Beruflich Dokumente
Kultur Dokumente
G. Lodewijks
There are several standards, like DIN 22131 Part 4, that prescribe a design f o r a belt
splice of a specific belt class. The design normally consists of a prescription of t h e
splice length, the right angle, and t h e actual layout pattern of plies or cords. There
are however, no standards t h a t explain the relationship between the design of a belt
splice and the specific application which t h a t splice has t o perform. W h a t for
example, is the effect of the belt speed; the conveyor length; the relaxation
distances between pulleys; the pulley diameter; transition distances; and the
conveyor dynamics on the performance of a splice? How does one ensure t h a t belt
splices do not jeopardize the safety of a belt conveyor?
1. INTRODUCTION
Conveyor belts are produced in pieces of a certain length and rolled into a roll. This
length is determined by the m a x i m u m belt roll diameter and/or the maximum
allowable transport weight. The average length of belting on a roll is about 300 m. In
order t o make a belt endless, a splice is required. Since most major belt conveyors
need an endless belt longer than 300 m, multiple splices are necessary. A splice is the
weakest linl< in a conveyor belt. In addition, the splice strength is in t i m e reduced by
fatigue. To ensure that a belt conveyor operates safely during its intended lifetime,
the splice needs t o be carefully designed. Splice designs are standardized by
standards lil<e DIN 22131 - Part 4 (1). However, a splice is never a 'one size fits ail'.
This paper therefore describes the fundamentals of splice design that assist in t h e
design of a belt splice which safely operates in a specific application. The focus is on
steel cord belts.
When considering a conveyor belt there are t w o components that determine the
technical lifetime of a belt: the condition of the belt covers, in particular the t o p
cover, and the splices. The t o p cover thickness is chosen so t h a t the anticipated wear
over the lifetime of the belt is such that some t o p cover rubber still remains at t h e
end of the belt's life. Splices need to be designed in such a way that the fatigue life of
the splices in the belt exceed the lifetime of the overall belt. The t o p cover thickness
selection is not discussed in this paper.
In a splice, ttie normal layout of the conveyor belt carcass is discontinued and t h e
end of the one belt is connected w i t h the end of t h e adjacent belt by means of a
splice. Figure 1 shows an open splice of a steel cord belt that illustrates a specific
pattern of the splice cables. As can be seen, the cables of b o t h ends are laid in such a
pattern that they overlap. In between this cable overlap zone, rubber strips are
inserted. These rubber strips, after vulcanization of the splice, allow the transfer of
forces arising f r o m the belt tension f r o m one cable t o the other. This tension transfer
causes shear stress in these rubber strips. Therefore these strips are also called shear
panels. In practice, numerous splice patterns are possible, see for example Figure 2.
2. S-N CURVES
DIN 22131 - Part 4 describes a test that establishes the fatigue strength of a test
splice under a continuous varying dynamic load. Using this test, a curve that links t h e
number of load cycles N w i t h the shear stress in the belt splice can be d e t e r m i n e d .
This curve is called the S-N curve. In literature this curve is also called the W ö h l e r
curve. The test conveyor belt w i t h the splice to be tested is positioned around t w o
pulleys (Figure 3). One of the pulleys is able t o move and apply a certain tension on
the test belt. The diameter of the pulleys depends on the belt rating. The tension is
varied in a saw-tooth fashion between limits over a certain period of t i m e . A t o t a l
tension cycle takes the belt 18 rotations around the test rig. The lower stress level is
fixed at 6.67% of the rated braking strength of the installed test belt. The higher
tension is changed f r o m test t o test and the belt is tested until t h e splice breaks.
N f , c y c l e s t o failure
As said before, the test conveyor belt is subjected t o a fluctuating dynamic tension
causing a fluctuating dynamic stress in the belt. The m a x i m u m stress is Omax and the
m i n i m u m stress, at a belt tension of 6.67% of t h e belt's rated braking strength, is
Omin. The mean stress Om t h e n can be defined as
Different combinations of the mean stress and the alternating stress can give t h e
same lifetime f o r a splice. This can be visualized in a so-called constant life diagram,
(Figure 5).
(J ultimate stress
The end of the constant life diagram is f o r m e d by the belt's rated braking strength or
ultimate stress Ou. The t w o lines in Figure 5 indicate t w o different levels of live or in
this case N. The line t o use here is the line that represents N=10,000. That line
indicates the difference b e t w e e n a safe combination of the mean stress and the
alternating stress and an unsafe combination, also see Figure 6.
"unsafe"
(J.,
In literature ^ t w o approximations of the constant life curve are used. The first is the
approximation of Goodman (England, 1899)
Instead of testing a full steel cord belt splice, as specified by DIN 2 2 1 3 1 - Part 4, an
'H-block' can be used in combination w i t h the finite element m e t h o d . Figure 7 shows
an H-blocl< that is a block of vulcanized rubber normally w i t h t h r e e steel cords.
Variants w i t h five cables are also used. The steel cords are the same cords as t h e
steel cords used in the steel cord belt. The rubber o f t h e H-block is t h e same rubber
as the rubber used in the splice of the belt.
Figure 7. H-block
An H-block is designed in such a way that the shear stresses t h a t normally occur in
the envisioned total splice also occur in the H-block. Therefore the overlapping
lengths of the steel cords in the H-block as well as the pitch b e t w e e n t h e cables need
t o be carefully selected. Using a series of H-blocks and a tensile tester t h a t is used t o
subject the H-block t o a dynamic load curve enables the d e t e r m i n a t i o n of the S-N
curve of the H-block (with tension and not shear stress). Since the tensile tester
applies a force on the cables of the H-block, this force needs t o be translated t o a
shear stress in the shear panels between the steel cords. For this a finite e l e m e n t
model of the H-block can be used, (Figure 8). Therefore t h e c o m b i n a t i o n of the finite
element model of the H-block and the results of the tensile tests produce a t r u e S-N
curve linking shear stress to number of load cycle N. This S-N curve is also valid f o r
t h e total splice as long as the maximum stress in the total splice remains less t h a n
the endurance stress determined w i t h the H-block. For the design of t h e t o t a l splice,
a finite element model of the total splice needs t o be made. The advantage of the
test procedure w i t h H-blocks and finite element models versus a t o t a l splice test is
t h a t t h e H-block procedure is much faster and cheaper as it enables virtual
prototyping. The disadvantage is that some end users of conveyor belts do not
accept the procedure.
3. F L U a U A T I N G STRESS
Assume that a belt conveyor makes N revolutions or load cycles in its lifetime. During
Nl cycles the maximum stress is oi, d u r i n g N2 cycles t h e m a x i m u m stress is 02 etc.
The maximum stress used in the splice design calculations then is (2)
4. APPLICATION FACTORS
In Paragraph 3 the dependency of the stress on t h e load factor and the operational
conditions was m e n t i o n e d . Here, the impact of various belt conveyor design choices
on the life of a splice are discussed.
An important belt conveyor design choice is the belt speed. Depending on the nature
o f t h e bulk solid material t o be transported and on the length and application o f t h e
belt conveyor, a belt speed is selected. Normally, a rule of t h u m b can be used: fine
materials use a low belt speed, course materials a high belt speed, in-plant
conveyors run at a low speed whereas overland conveyors use a higher speed.
iVj,e„. = 15,768,000^ 6
The belt length has t h e opposite effect on the lifetime of t h e belt w h e n compared t o
the belt speed. The longer t h e belt conveyor, the fewer load cycles t h e conveyor belt
makes over a given period of time (Equation 6). This means t h a t generally, w i t h an
increase in the length of a belt conveyor, the length of t h e splice can decrease
because fewer load cycles allow f o r a higher maximum shear stress. In practice this is
relevant because it means t h a t long overland conveyors may require shorter splices
than t h e splice length prescribed by standards like DIN 2 2 1 3 1 . This leads t o a
reduction in splicing t i m e and costs.
After a belt splice passes a driven pulley t h e belt needs t o 'recover' f r o m t h e sudden
change in tension. The belt tension and thus stress before t h e driven pulley is higher
than after t h e driven pulley unless t h e system is regenerative. The belt needs t i m e t o
relax f r o m t h e change in tension and t h e elongation that follows. If t h e belt does n o t
have t h e o p p o r t u n i t y t o relax before it passes t h e next driven pulley, as in t h e case in
multiple driven pulleys, then a residual stress remains in t h e belt, w h i c h increases
the overall stress in t h e belt. This needs t o be accounted f o r in t h e c o m p i l a t i o n of a
cumulative load diagram.
Similar to the discussion on the pulley diameter, the transition f r o m a flat belt to a
troughed belt imposes an additional stress into the belt. This extra stress depends
primarily on the transition length, the belt w i d t h , the t r o u g h angle and the length of
the wing rolls. Usually, an increase in transition length leads to a decrease in belt
stress. The impact of the transition length on the splice design however, like t h e
pulley diameter, is limited.
6. CONCLUSIONS
Using Equation 5, the m a x i m u m stress t o use in the splice design is calculated. Using
the information f r o m the S-N curve, for which H-block tests are required, a proper
splice design can be made by using the finite element m e t h o d as demonstrated in
this paper.
1. DIN 22131 (1988), "Steel cord conveyor belts for hoisting and conveying", Deutsches
Institut Für Normung.
PROF G A B R I E L LODEWIJKS
Prof.dr.ir.Gabrie! Lodewijks
Delft University of Technology
Faculty of Mechanical, M a r i t i m e and Materials Engineering
Department of Marine and Transport Technology
Mekelweg 2
2628 CD, Delft
The Netherlands
Phone : + 3 1 1 5 278 8793
Fax : + 3 1 15 278 1397
e-mail : g.lodewijks@tudelft.nl or g.lodewijks@conveyor-experts.com
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